Process and device for manufacturing free-flowing metal foam

Abstract

Device for manufacturing a metal foam. The device includes at least two feed pipes for introducing gas. The at least two feed pipes are arranged next to one another. Each of the at least two feed pipes project into a foamable melt. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

1. A metal foam manufacturing device for manufacturing a metal foam usable with a mold for allowing the metal foam to solidify therein, the device comprising:
 a nozzle arrangement of the metal foam manufacturing device structured and arranged to form bubbles which abut one another and form interstructures, the nozzle arrangement comprising at least two feed pipes for introducing gas into a foamable melt and spaced to form the bubbles which abut one another and form the interstructures; 
 a pressure chamber of the metal foam manufacturing device arranged under a nozzle assembly of a metallurgical vessel of the metal foam manufacturing device; 
 the at least two feed pipes being arranged next to one another and projecting upwards from the nozzle assembly and into the foamable melt; and 
 the mold receiving therein the metal foam formed from the foamable melt, whereby the metal foam is allowed solidify in the mold, 
 wherein the gas is injected into the foamable melt through the at least two feed pipes and from the pressure chamber. 
 
     
     
       2. The device of  claim 1 , wherein the at least two feed pipes are arranged at a distance from one another. 
     
     
       3. The device of  claim 2 , wherein a size of individual bubbles is based upon the distance. 
     
     
       4. The device of  claim 1 , wherein the metal foam is a free-flowing metal foam having a monomodal distribution of cavity dimensions. 
     
     
       5. The device of  claim 1 , further comprising at least one additional feed pipe, wherein each of the feed pipes projects into a molten mass. 
     
     
       6. The device of  claim 5 , wherein the at least one additional feed pipe is arranged offset relative to one of the at least two feed pipes. 
     
     
       7. The device of  claim 6 , wherein the at least one additional feed pipe is spaced at an equal distance from each of the at least two feed pipes. 
     
     
       8. The device of  claim 1 , wherein the at least two feed pipes comprise ends which are substantially similarly shaped. 
     
     
       9. The device of  claim 8 , wherein the ends are arranged on at least one of a common plane and a common surface. 
     
     
       10. The device of  claim 1 , wherein the at least two feed pipes are substantially similarly shaped and sized. 
     
     
       11. The device of  claim 10 , wherein the ends are arranged on at least one of a common plane and a common surface. 
     
     
       12. A metal foam manufacturing device for manufacturing a metal foam usable with a mold for allowing the metal foam to solidify therein, the device comprising:
 a pressure chamber of the metal foam manufacturing device arranged under a nozzle assembly of a metallurgical vessel of the metal foam manufacturing device; 
 the nozzle assembly of the metal foam manufacturing device being structured and arranged to form bubbles which abut one another and form interstructures; 
 multiple rows of feed pipes for introducing gas into a foamable melt arranged above the nozzle assembly and being spaced to form the bubbles which abut one another and form the interstructures; 
 each feed pipe projecting upwards from the nozzle assembly into the foamable melt and having ends which are substantially similarly shaped; and 
 the mold receiving therein the metal foam formed from the foamable melt, whereby the metal foam is allowed solidify in the mold, 
 wherein the gas is injected into the foamable melt through the feed pipes and from the pressure chamber. 
 
     
     
       13. The device of  claim 12 , wherein the feed pipes are arranged at a distance from one another and a size of individual bubbles is based upon the distance. 
     
     
       14. The device of  claim 12 , wherein the metal foam is a free-flowing metal foam having a monomodal distribution of cavity dimensions. 
     
     
       15. The device of  claim 12 , wherein each subsequent row is laterally offset by half of a distance between the feed pipes. 
     
     
       16. The device of  claim 12 , wherein the feed pipes are spaced at an equal distance from each other. 
     
     
       17. The device of  claim 12 , wherein the device has three rows of feed pipes. 
     
     
       18. A metal foam manufacturing device for manufacturing a metal foam usable with a mold for allowing the metal foam to solidify therein, the device comprising:
 a pressure chamber of the metal foam manufacturing device arranged under a nozzle assembly of a metallurgical vessel of the metal foam manufacturing device; 
 the nozzle assembly of the metal foam manufacturing device being structured and arranged to form bubbles which abut one another and form interstructures; 
 multiple rows of feed pipes for introducing gas into a foamable melt arranged above the nozzle assembly and being spaced to form the bubbles which abut one another and form the interstructures; 
 each subsequent row of feed pipes being laterally offset; 
 each feed pipe projecting upwards from the nozzle assembly and by an equal amount into the foamable melt; and 
 the mold receiving therein the metal foam formed from the foamable melt, whereby the metal foam is allowed solidify in the mold, 
 wherein a gas is injected into the foamable melt through the feed pipes and from the pressure chamber. 
 
     
     
       19. The device of  claim 18 , wherein each subsequent row of feed pipes is laterally offset by half of a distance between the feed pipes. 
     
     
       20. The device of  claim 18 , wherein the feed pipes of a respective row are spaced at an equal distance from each other.